ZK60A Forged And CNC Machined Magnesium Component

ZK60A Forged And CNC Machined Magnesium Component With High Precision For Propeller

Besides supplying magnesium alloy plate, rod, billet, bar, sheet, wire forgings, castings and profile, XYMCO also has a close cooperated machining shop with excellent CNC machining capability.

Here is some data about the magnesium material's machining:

CUTTING POWER & MACHINABILTY

The mean specific cutting force (ks1.1) of magnesium is 280 N/mm 2 , this is much lower than that of aluminium (approx 640 N/mm 2 ). The result of this means that there is a reduced load on the cutter and tool body allowing higher cutting speeds and feed rates.

The power required to remove a given amount of magnesium compared to another metal is lower. An indication of the relative power required to machine various metals is shown in Table 1. The American Iron and Steel Institute (AISI) also ranked the machinabilty of metals, using high-speed steel (HSS) tooling and taking 160 Brinell B1112 steel as the arbitrary reference point, giving it a value of 100%. Any value greater than this indicates that the material is easier to machine and conversely any value lower indicates the material is more difficult to machine.

Table 1 – RELATIVE POWER & COMPARATIVE

MACHINABILITY OF METALS

TOOL MATERIAL

Although HSS tooling can be used and is often employed in twist drills, taps and broaches, carbide is the preferred tooling material for most machining operations on magnesium alloys. Carbide gives a balance of economics and the ability to perform high volume production runs. It also gives a good surface finish, however, if a superior surface quality is required with long series at high production volumes, polycrystalline diamond (PCD) should be considered. PCD tools are extremely wear resistant and their use eliminates the occurrence of built-up edge (BUE) on the tool. This is due to the low adhesion tendency of PCD.

BUE is more commonly encountered while machining magnesium-aluminium alloys or when machining is carried out at very high speeds. The use of uncoated carbide tools, which allows sharper cutting edges, reduces material build up.

It is therefore recommended that uncoated carbide tools be used for machining magnesium alloys as these have a cost advantage over PCD. Although where economics allow PCD should be the material of choice.

Table 2 – COMPARATIVE MACHINABILITY OF METALS

SPEEDS, FEEDS & DEPTHS OF CUT
The potential for high speed machining of magnesium alloys is usually only limited by the stability of the component in the clamping device, chip extraction or the rotation speed or accuracy limits of the tool or machine. Some relative cutting speeds using HSS tools are given in Table 2. Cutting speeds are also dependant on the tool material. Higher speeds can be enjoyed with the use of carbide or poly-crystalline
diamond (PCD) tooling.
In general, cutting speeds are between 200 –1800 m/min with feed rates greater than 0.25 mm/rev for turning and boring operations. Face milling however, can be carried out at speeds up 3000m/min (10000 ft/min) with feed rates between 0.05 and 0.5 mm/tooth. Depths of cut can be up to 12mm. It should be noted that certain drilling, reaming and tapping operations are unsuitable for high speed
machining.
Coarse feed rates should be employed in order to produce large chips rather than fine swarf. In general heavy feeds produce short well broken chips, medium feeds produce short partially broken chips and light feeds produce long curled chips. Well broken chips are desirable and are normally produced during the machining of magnesium.

Wrought magnesium tooling plate (Alloy AZ31B) has the following benefits and characteristics:

Xi'an Yuechen Metal Products. Co., Ltd. (XYMCO) - a manufacturer specialized in the magnesium tooling plate, Magnesium alloy plate, magnesium alloy slab, magnesium alloy sheet, magnesium alloy bar, magnesium alloy tube, magnesium alloy billet, magnesium alloy rod, magnesium alloy rod, magnesium alloy pipe, magnesium welding wire, magnesium alloy profile, magnesium alloy forging, magnesium alloy casting, magnesium alloy machining part.
We comply with the specifications: AMS 4377G, AMS 4382, ASTM B90/B90M and ASTM B107.
Material grades: AZ31B, AZ61A, AZ80A, ZK60, AM50, AM60, AZ91, EQ21, EZ33, EV31, WE43, WE54 and ZE41.
 
Our main products and capacities are as follows:
1. Magnesium tooling plate: Max. Thickness: 300mm; Max. Width: 3000mm; Max. Length: 6000mm
2. Magnesium alloy slab: Max. Size: 400 x 1000 x 2500mm
3. Magnesium alloy sheet: Min. Thickness: 0.5mm; Max. Width: 600mm; Max. Length: 2000mm
4. Magnesium cast bar: Min. Diameter 90mm; Max. Diameter: 600mm; Max. Length: 6000mm
5. Magnesium extrusions:
Round tube: Max. OD 600mmx thickness 125mm Square tube: 430 x 430mm Flat bar: 920 x 160mm
U-Shape: 800 x 300mm Rectangular: 700 x 200mm
6. Magnesium alloy machined part according to customer’s design
7. Magnesium anode as per customer’s design

Hot rolled AZ31B Magnesium alloy plate has good carving processing performance.
Because of its outstanding characteristics of magnesium plate engraving of low density, high specific stiffness, good damping property, environment friendly and no pollution, Recyclable good performance, known as the twenty-first Century green metal structure material. The magnesium plate engraving and mechanical processing of parts, in national defense, aerospace, electronic communication, rail transportation, medical equipment, printing plate, magnesium board carving mold and other fields, and has wide application prospect.
 
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